Underwater electrical connection and termination assemblies

ABSTRACT

An underwater electrical connection assembly may include a contact pin including an axially extending conductive core and an axially extending annular insulation portion around said conductive core, a front end portion of the conductive core having an electrical contact surface, a rear end portion of the conductive core having an electrical contact surface, and an intermediate portion of the conductive core extending axially at an intermediate location between the front and rear end portions, wherein the rear end portion of the conductive core of the pin has a diameter larger than the diameter of the intermediate portion thereof, and wherein the annular insulation portion includes an inner insulating layer around the intermediate portion of the conductive core and an insulating sleeve around the inner insulating layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/646,964 filed May 15, 2012. The contents of which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to underwater electrical connection assembliesand to termination assemblies for underwater cables.

BACKGROUND

Underwater electrical connection assemblies are known and have been inwidespread use in the offshore oil and gas industry for many years. Anexample is shown in GB 2192316 A, which discloses an underwaterconnector with a first connector part and a second connector part whichare capable of being mated and de-mated underwater. In this known designthe first connector half comprises a receptacle for receiving a plug ofa second connector half. An electrical contact pin projects axially inthe receptacle and when the plug is inserted in the receptacle the pinenters the plug to make an electrical connection with a contact socketinside the plug. The electrical connection is established in a protectedoil or gel filled environment contained in a chamber which is pressurebalanced with respect to the pressure outside of the connector, therebyreducing the tendency for water or contaminants to enter the connectionchamber.

Underwater electrical connectors are used for communicating electricsignals for instrumentation and also for electric power applications. Inrecent years there has been a demand for connector assemblies capable ofhandling high voltages, typically tens of kilovolts. An example of ahigh voltage underwater electrical connector is described in GB 2361365A. The use of high voltages creates issues concerning the electric fieldaround the live components, and the electric stress created ininsulating components in the case of high electric field gradients.Insulating materials can suffer from breakdown of the materials above acritical level of electric field gradient. The drawing of high currentsthrough the connector raises issues about heating and it is desirable toavoid hot spots which can lead to reduced efficiency and possiblematerial degradation or even failure.

A known high voltage connector assembly is the SpecTRON (trade mark)produced by Expro Connectors and Measurements of the United Kingdom. Theelectrical contact pin of the receptacle connector half has an axiallyextending conductive core and an axially extending annular insulationportion around the axially extending conductive core. The rear endportion of the conductive core has a radially outwardly facingelectrical contact surface, for connection to another component to therear of the connector, such as an underwater cable. The front endportion of the conductive core also has a radially outwardly facingelectrical contact surface, in this case for making contact with asocket provided in the plug connector half. The contact pin projectsforwardly from a support and when the connector halves are fully matedthe base part of the contact pin, nearest the support, extends through aseal provided at the entry to the plug connector half. In the region ofthis base part the contact pin has an electrically conductive earthshield arranged radially outwardly of the annular insulation portion.This earth shield serves to shield the seal at the entry to the plugconnector half from electrical stress. In the mated condition of theconnector assembly the base part of the pin immediately adjacent to thesupport is exposed to the surrounding water, and the earth shield cantherefore also serve to protect the annular insulation portion from theeffects of ambient water, and thus avoids water absorption that oftenleads to electrical degradation or failure. It also providesverification testing advantages, because the earth profile is notdependent on the ambient water i.e. it is independent of theenvironment.

A certain minimum thickness is required for the annular insulationportion between the conductive core and the earth shield, to avoidexcessively high electrical stresses in the insulation material. Theoutside diameter of the earth shield is the same as the outside diameterof the insulation portion forwardly thereof, so that the contact pin hasa constant diameter along all of its length which is to be inserted inthe entry seal of the plug connector half. In order to comply with theseconstraints, for a given overall diameter of the contact pin, there is amaximum diameter imposed on the conductive core where it passes throughthe earth shield.

During construction of this known connector assembly, the annularinsulation portion is provided by an insulating sleeve which is insertedover the conductive core from the rear. The rear end portion of theconductive core, where the radially outwardly facing electrical contactsurface is provided, therefore has the same diameter as the part of thecore which passes through the conductive earth shield.

SUMMARY

One embodiment provides an underwater electrical connection assemblycomprising a contact pin comprising an axially extending conductive coreand an axially extending annular insulation portion around saidconductive core, a front end portion of the conductive core having anelectrical contact surface, a rear end portion of the conductive corehaving an electrical contact surface, and an intermediate portion of theconductive core extending axially at an intermediate location betweenthe front and rear end portions, the rear end portion of the conductivecore of the pin having a diameter larger than the diameter of theintermediate portion thereof, and the annular insulation portioncomprising an inner insulating layer around the intermediate portion ofthe conductive core and an insulating sleeve around the inner insulatinglayer.

In a further embodiment, the inner insulating layer is made of amaterial which has set or hardened in a space between the insulatingsleeve and the intermediate portion of the conductive core.

In a further embodiment, the conductive core has one or more channels atits front end communicating with a space occupied by the innerinsulating layer.

In a further embodiment, the assembly comprises a socket member having asocket receiving the rear end portion of the conductive core forelectrical engagement with the electrical contact surface thereof.

In a further embodiment, the contact pin has an electrically conductiveearth shield arranged radially outwardly of the intermediate portion ofthe conductive core.

In a further embodiment, the assembly comprises first and secondconnector parts capable of being mated underwater, wherein the firstconnector part comprises the contact pin.

Another embodiment comprises an underwater electrical connectionassembly comprising: a contact pin comprising an axially extendingconductive core with a front portion having a front electrical contactsurface and a rear portion having a rear electrical contact surface, andan annular insulation portion around said conductive core extendingaxially rearwardly from the front portion of the conductive core; acollar mounted on the conductive core forwardly of the rear electricalcontact surface thereof, the collar being axially split and having aradially outer threaded surface; and a conductive sleeve having aradially inner threaded surface in engagement with the radially outerthreaded surface of the collar so as to mount the conductive sleeve onthe conductive core.

In a further embodiment, the rear portion of the conductive core, atleast where the rear electrical contact surface is provided, has adiameter which is larger than that of a part of the conductive coreforwardly of the collar.

In a further embodiment, the conductive sleeve engages with the annularinsulation portion.

In a further embodiment, the conductive sleeve extends forwardly of thecollar.

In a further embodiment, the conductive sleeve extends rearwardly of thecollar.

In a further embodiment, the collar is received in an annular recessaround the rear portion of the conductive core.

In a further embodiment, the assembly comprises an alignment dowelextending radially between the conductive core and the collar.

In a further embodiment, the assembly comprises an axial channelextending from the front of the engaged radially inner and radiallyouter threaded surfaces to the rear thereof.

In a further embodiment, the axial channel is formed in the conductivesleeve.

In a further embodiment, the conductive sleeve has an abutment surfacein engagement with the annular insulation portion, and a radially outerportion disposed radially outwardly and forwardly of the abutmentsurface.

Another embodiment comprises an underwater electrical connectionassembly comprising: a contact pin comprising an axially extendingconductive core with front and rear portions each having a respectiveelectrical contact surface, and an annular insulation portion aroundsaid conductive core extending axially rearwardly from the front portionof the conductive core; and a conductive sleeve mounted on the rearportion of the conductive core, the conductive sleeve having an abutmentsurface in engagement with the annular insulation portion, and aradially outer portion disposed radially outwardly and forwardly of theabutment surface.

In a further embodiment, the conductive sleeve has an annular surfacewhich is slanted with respect to the axial direction, and which extendsradially outwardly from the abutment surface to the radially outerportion.

In a further embodiment, insulating material is provided in a regionrearwardly of the abutment surface.

Another embodiment comprises an underwater electrical connectionassembly comprising: a contact pin comprising an axially extendingconductive core with front and rear portions each having a respectiveelectrical contact surface, and an annular insulation portion aroundsaid conductive core extending axially rearwardly from the front portionof the conductive core; a chamber containing insulating fill materialwhich surrounds the annular insulation portion of the contact pin whereit extends axially rearwardly from a first axial position; and an earthguide member extending rearwardly from said first axial position to asecond axial position rearward of the first axial position, said earthguide member extending rearwardly from adjacent to the annularinsulation portion at said first axial position to radially outward ofsaid annular insulation portion at said second axial position.

In a further embodiment, the earth guide member is substantiallyconical.

In a further embodiment, as viewed in axial cross section, at least apart of the earth guide member has a profile which is concave.

In a further embodiment, the rear of the earth guide member is sealinglyconnected to a gland member around the insulating fill material.

In a further embodiment, the assembly comprises a fill opening for theintroduction of fill material to the chamber.

In a further embodiment, the assembly comprises a second chamber outwardof the first mentioned chamber and containing fill material.

In a further embodiment, the assembly comprises a conductive sleevemounted on the rear portion of the conductive core, the conductivesleeve extending forwardly to a position radially inwardly of the earthguide member.

In a further embodiment, the conductive core has a portion of increasingdiameter in the rearward direction, this portion being located radiallyinwardly of the earth guide member.

Another embodiment comprises a termination assembly for an underwatercable, comprising: a pin having an axially extending conductive core andan axially extending annular insulation portion around said conductivecore; a conductive socket member for making an electrical connectionwith a conductor of an underwater cable and having a front socket, thefront socket receiving a rear end portion of the conductive core of thepin; an electrical contact terminal in the front socket makingelectrical contact with said rear end portion; and a locking member forlocking said rear end portion in the front socket, the locking memberbeing disposed rearwardly of the electrical contact terminal.

In a further embodiment, said locking member engages an intermediatemember which is mounted on the conductive core of the pin.

In a further embodiment, said intermediate member is mounted to an axialrear end of the rear end portion of the conductive core.

In a further embodiment, said intermediate member has an axialprojection extending into an axial socket in the rear end portion of theconductive core.

In a further embodiment, said intermediate member has an engagementportion for engagement by the locking member, the engagement portionhaving a diameter wider than the diameter of the axial projection.

In a further embodiment, said intermediate member has an annular channelfor receiving the locking member.

In a further embodiment, said intermediate member is screw mounted onthe conductive core of the pin.

Another embodiment comprises a termination assembly for an underwatercable, comprising: a cable termination chamber housing having anattachment portion; a pin for electrical connection to the cable; a pinhousing for the pin; and an attachment flange for attachment to the pinhousing so as to protrude radially therefrom, the attachment flangebeing for attachment to the attachment portion of the cable terminationchamber housing, and the attachment flange being provided in at leasttwo parts so that when the parts are to be attached to the pin housingthey can be moved laterally into engagement therewith.

In a further embodiment, the attachment flange is arranged to be boltedto the pin housing in the radial direction and to be bolted to theattachment portion of the termination chamber housing in the axialdirection.

In a further embodiment, the assembly comprises a radially extendingdowel extending between each attachment flange part and the pin housing.

In a further embodiment, the assembly comprises at least threeattachment flange parts.

In a further embodiment, the assembly comprises exactly four attachmentflange parts.

In a further embodiment, the attachment flange parts extend in thecircumferential direction and have opposite circumferential ends, eachsuch end being in contact with or adjacent to an end of acircumferentially adjacent attachment flange part when all the parts areattached to the pin housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments will be explained in more detail below based onthe schematic drawings, wherein:

FIG. 1 is an axial cross sectional view of a first connector part havinga contact pin;

FIG. 2 is an enlarged end view from the front of the first connectorpart, viewed from the left as seen in FIG. 1;

FIG. 3 is a partially cut away and partially exploded perspective viewof the connector part;

FIG. 4 is an enlarged view of part of FIG. 1 showing a lockingarrangement between a rear end portion of a conductive core of a pin anda conductive socket sleeve;

FIG. 5 is an exploded perspective view of the locking arrangement;

FIG. 6 is an exploded perspective view of an arrangement for mounting aconductive sleeve on a rear portion of the conductive core of thecontact pin;

FIG. 7 is an enlarged view of part of FIG. 1 showing the conductivesleeve mounting arrangement and also an earth guiding arrangement;

FIG. 8 is a perspective view of some of the components shown in FIG. 6;and

FIG. 9 is a partially cut away perspective view of a second connectorpart with which the first connector part is mateable.

DETAILED DESCRIPTION

Some embodiments provide an underwater electrical connector assemblyhaving an improved contact pin design.

For example, one embodiment provides an underwater electrical connectionassembly comprising a contact pin comprising an axially extendingconductive core and an axially extending annular insulation portionaround said conductive core, a front end portion of the conductive corehaving an electrical contact surface, a rear end portion of theconductive core having an electrical contact surface, and anintermediate portion of the conductive core extending axially at anintermediate location between the front and rear end portions, the rearend portion of the conductive core of the pin having a diameter largerthan the diameter of the intermediate portion thereof, and the annularinsulation portion comprising an inner insulating layer around theintermediate portion of the conductive core and an insulating sleevearound the inner insulating layer.

With this arrangement, the diameter of the intermediate portion of theconductive core does not limit the diameter of the rear end portion ofthe conductive core having the electrical contact surface, which has adiameter larger than the diameter of the intermediate portion thereof.As this is a critical region, where electrical contact between thecomponents is made, it is advantageous to be able to provide arelatively large electrical contact surface. Any tendency of theconnector to overheat in this region can be reduced or avoided.

The larger diameter of the rear end portion of the conductive core canalso contribute to increased stiffness and strength of the contact pin.

In the case of the known SpecTRON 10 assembly mentioned above, theconductive core has an intermediate portion with the same diameter asthe rear end portion where its rear electrical contact surface isprovided. It is therefore a simple matter to insert an insulating sleeveonto the conductive core by passing it forwardly from the rear. However,in some embodiments of the underwater electrical connection assembly therear end portion of the conductive core has a diameter larger than thediameter of the intermediate portion disposed forwardly thereof and sothe known assembly method is not applicable. The inventors haverecognised that by using a two part annular insulation portion itbecomes possible to provide the required insulation around a conductivecore intermediate portion which has a smaller diameter than the rear endportion thereof.

The insulating sleeve may be a prefabricated sleeve. During assembly,the insulating sleeve may for example be placed on the conductive coreby being moved forwardly over the rear end portion, to surround theintermediate portion. The insulating sleeve may be made of athermoplastic.

The inner insulating layer may be introduced as a flowable material,such as a liquid, which then sets in an annular space between theinsulating sleeve and the intermediate portion of the conductive core,to form the inner insulating layer. The inner insulating layer may bemade of a material which has set or hardened in the space between theinsulating sleeve and the intermediate portion of the conductive core.The insulating sleeve which forms part of the annular insulation portionmay serve to define a space into which the flowable material isintroduced.

The flowable material may be introduced into the annular space from thefront end of the conductive core, for example via one or more channelsin the insulating sleeve and/or in the conductive core. The flowablematerial may then flow rearwardly into the annular space. It may flowfurther rearwardly at least as far as the rear of the insulating sleeve.

The inner insulating layer may be made of a thermoplastic.

The electrical contact surface of the rear portion of the conductivecore may be a radially outwardly facing electrical contact surface. Thistakes full advantage of the relatively large diameter of the rearportion, by using the external area thereof for making electricalcontact with another component.

The assembly may comprise a socket member having a socket receiving therear end portion of the conductive core for electrical engagement withthe radially outwardly facing electrical contact surface thereof.

In some embodiments of the contact pin an electrically conductive earthshield is arranged radially outwardly of the intermediate portion of theconductive core. The outside diameter of the earth shield may be thesame as the outside diameter of the insulation portion forwardlythereof, so that the contact pin has a constant diameter along all ofits length which, in use, is to be inserted in the entry seal of anothercomponent. Therefore, when the assembly is connected underwater to suchother component, the earth shield can serve to protect the seal fromhigh electrical stresses and the insulating sleeve from exposure toambient water.

The connection assembly may comprise a conductive socket member having asocket which receives the conductive core rear portion in electricalengagement with the rear electrical contact surface thereof. The socketmay be adapted for connection to another conductor, such as a conductorof a cable. The socket member may have a second socket for receivingsuch a conductor.

The assembly may comprise first and second connector parts capable ofbeing mated underwater, wherein the first connector part comprises thecontact pin as discussed herein. The second connector part may comprisea contact terminal for engagement by the electrical contact surface atthe front of the conductive core to establish an electrical connectionwhen the first and second connector parts are mated. The electricalconnection may be established in a protected oil or gel filledenvironment in the second connector part, such as a chamber. The chambermay be pressure balanced with respect to pressure outside of theconnector, for example by having a flexible wall.

The second connector part may comprise an entry seal for receiving thecontact pin. If the contact pin has an electrically conductive earthshield arranged radially outwardly of the intermediate portion of theconductive core, the earth shield may extend in the entry seal of thesecond connector part when the connector parts are fully mated.

In some embodiments of the assembly, in the region of the contact pinwhere it is to enter the second connector part, the pin may have anumber of layers, comprising a central conductive core, an innerinsulating layer around the core, an insulating sleeve around the innerinsulating layer, and an earth shield around the insulating sleeve.

Other embodiments provide an underwater electrical connection assemblywith an improved arrangement for mounting a conductive member on aconductive core of a contact pin.

In the known SpecTRON 10 assembly discussed above the conductive core ofthe contact pin has a constant diameter over its length extendingrearwardly from a front electrical contact surface thereof. Theconductive core is surrounded by an insulating sleeve. The front end ofthe insulating sleeve abuts against a wide diameter portion of theconductive core, this wide diameter portion also providing the frontelectrical contact surface of the contact pin for engagement in acorresponding socket of the plug connector part. The insulating sleeveis held in the abutting relationship with the front wide diameterportion by a nut at the rear of the conductive core. The nut has aninternal thread engaged with an external thread on the conductive corerear portion. The nut engages the rear end of the insulating sleeve andthus clamps it against the wide diameter portion at the front of theconductive core. The conductive core extends rearwardly behind the nutto where the rear end portion of the conductive core is received in thefront socket of a socket member to make electrical contact with acontact terminal in the front socket. During assembly of the contactpin, in order for the nut to engage with the thread on the conductivecore it is necessary for it to be passed over the rear end portion in aforward direction. As a result, the diameter of the rear end portion issmaller than the internal diameter of the female thread on the nut.

One embodiment provides an underwater electrical connection assemblycomprising: a contact pin comprising an axially extending conductivecore with a front portion having a front electrical contact surface anda rear portion having a rear electrical contact surface, and an annularinsulation portion around said conductive core extending axiallyrearwardly from the front portion of the conductive core; a collarmounted on the conductive core forwardly of the rear electrical contactsurface thereof, the collar being axially split and having a radiallyouter threaded surface; and a conductive sleeve having a radially innerthreaded surface in engagement with the radially outer threaded surfaceof the collar so as to mount the conductive sleeve on the conductivecore.

By mounting an axially split collar on the conductive core, the collarhaving a radially outer threaded surface for engaging with a radiallyinner threaded surface of a conductive sleeve, the internal diameter ofthe threaded surface of the conductive sleeve may be increased comparedto the diameter it would need to be if threadedly engaging theconductive core directly. This enables the diameter of the conductivecore rearwardly of the collar to be made larger, if desired. Thearrangement permits the rear portion of the conductive core having therear electrical contact surface to have a relatively large diameter.This is beneficial in that a large electrical contact area can beprovided, allowing reduced resistance across the connection and reducingthe temperature when a current flows.

In some embodiments, the rear portion of the conductive core, at leastwhere the rear electrical contact surface is provided, has a diameterwhich is larger than that of a part of the conductive core forwardly ofthe collar.

The conductive sleeve may engage with the annular insulation portion. Itmay therefore serve to hold the annular insulation portion in position,for example by preventing it from moving rearwardly relative to theconductive core. The annular insulation portion may comprise aninsulating sleeve which is clamped between the front portion of theconductive core and the conducting sleeve in the axial direction. Theconductive sleeve can usefully serve this purpose,

The conductive sleeve can serve to provide heat dissipation of theconductive core. The conductive sleeve may be arranged on the rearportion, for example forwardly of the rear electrical contact surfacethereof. This portion has a tendency to get hot at higher currentsbecause of the electrical connection via the rear electrical contactsurface to another component behind the contact pin, such as to a socketof a socket member.

The collar may be made of an electrically conductive material, e.g., ametallic material. Electrically conductive materials, such as metals,are also good thermal conductors. The collar can then serve to transmitheat from the conductive core to the conductive sleeve, assisting theheat dissipation function of the conductive sleeve.

If the collar is made of an electrically conductive material, it canprovide an electrical connection between the conductive core and theconductive sleeve. During use of the assembly, the conductive sleeve maythen adopt the same electric potential as the conductive core. Theinterengaging threads of the collar and the conductive sleeve, and thearea around these threads, can then be at the same electric potentialand therefore not subject to electrical stress which could lead topartial electrical discharge and increased heat. The conductive sleevecan effectively serve to cloak the threads and the area adjacent to thethreads from an electric field gradient. The conductive sleeve mayextend forwardly of the collar in order to take full advantage of thiscloaking effect.

By being axially split, during construction of the contact pin thecollar does not need to be positioned on the conductive core by beingpassed over one or other end thereof. Rather, the collar can bepositioned on the conductive core by lateral engagement therewith. Theinside diameter of the collar therefore does not need to be larger thaneither end portion of the conductive core, allowing the rear portion(and if desired the front portion) of the conductive core to have awider diameter than the inside diameter of the collar.

The radially inwardly facing surface of the split collar, which makescontact with the conductive core, may be substantially smooth.

The collar may be axially split by one axial split line or by aplurality thereof. It may have two axial split lines. It may be providedin two parts, each arranged to extend round half the circumference ofthe conductive core. The collar may be initially formed as a cylinderand the thread formed on the outside of the cylinder, before the collaris axially split.

The collar may be received in an annular recess around the conductivecore. This assists during manufacture of the contact pin in locating thecollar in the correct axial position. There may be an alignment dowelextending radially between the conductive core and the collar. This canassist in locating the collar in the correct rotational position and thecorrect axial position. In the arrangements discussed above wherein theconductive sleeve cloaks the collar from an electric field gradient, theconductive sleeve can also function to cloak the annular recess ifprovided, and the dowel if provided.

The annular insulation portion may be at least partly formed by flowablematerial. During manufacture of the contact pin, the flowable materialmay be introduced around the conductive core and allowed to set orharden. The flowable material may be solid once it has set. The materialmay be introduced so as to occupy one or more cavities around oradjacent to the conductive core. If the annular insulation portioncomprises an insulating sleeve this may serve to enclose a space aroundthe conductive core. The cavity may be occupied by the flowable materialonce solidified.

The flowable material may be introduced from the front of the contactpin. The front portion of the conductive core may for example have anaxially extending passage, which may allow introduction of flowablematerial. Such a passage may then connect with the one or more cavitiesaround or adjacent to the conductive core.

In one embodiment the contact pin is arranged to permit flowablematerial to be introduced from the front thereof during formation of theannular insulation portion, and the contact pin has an exit point forthe flowable material at the rear of the conductive sleeve.

The connection assembly may comprise a conductive socket member having asocket which receives the conductive core rear portion in electricalengagement with the rear electrical contact surface thereof. The socketmay be adapted for connection to another conductor, such as a conductorof a cable. The socket member may have a second socket for receivingsuch a conductor.

The socket member may have an outside diameter substantially equal tothe outside diameter of the conductive sleeve. The rear of theconductive sleeve may be adjacent to the socket member. In use, the rearportion of the conductive core, the conductive sleeve and the socketmember may all be at the same electric potential and the exit point offlowable material at the rear of the conductive sleeve is at leastpartly surrounded by these three components and so is not subject to anyelectric field gradient. Thus the flowable material exit point, wherepotentially air may be trapped during the contact pin constructionprocedure, is cloaked and is not subject to electrical stress whichmight otherwise cause partial electrical discharge and heat generation.

Any space between the conductive sleeve and the conductive core may befilled with insulating material. This can be achieved by using flowablematerial to occupy any such space. The assembly may comprise an axialchannel extending from the front of the engaged radially inner andradially outer threaded surfaces to the rear thereof. The axial channelcan serve to allow e.g. flowable material to flow from in front of thecollar to the rear thereof. The provision of an axial channel can ensurethat there are no pockets of air between the conductive sleeve and theconductive core.

There may be a plurality of axial channels. The or each axial channelmay be formed in the conductive core or the conductive sleeve, or partlyin each of these components. The or each axial channel may be formed inthe conductive sleeve.

As discussed above the conductive sleeve may engage with the annularinsulation portion, and this may allow the conductive sleeve to hold theinsulation portion in position by preventing it from moving rearwardlyrelative to the conductive core. The conductive sleeve may have anabutment surface in engagement with the annular insulation portion.

In one arrangement, the conductive sleeve has an abutment surface inengagement with the annular insulation portion, and a radially outerportion disposed radially outwardly of and forwardly of the abutmentsurface. In use, providing the conductive sleeve is at the same electricpotential as the conductive core, with such an arrangement the forwardlydisposed radially outer portion of the conductive sleeve can protectfrom electric stress the region where the conductive sleeve abutmentsurface and the annular insulation portion are in engagement. In effect,the radially outer portion can cloak the region in question. The regioncan be at substantially the same electric potential as the conductivecore and the conductive sleeve, and therefore not subject to partialelectrical discharge and hence heat generation. Even if an air pocketexists in this region such a partial electrical discharge is avoided.

The assembly may comprise first and second connector parts capable ofbeing mated underwater, wherein the first connector part comprises thecontact pin as discussed herein. The second connector part may comprisea contact terminal for engagement by the electrical contact surface atthe front of the conductive core to establish an electrical connectionwhen the first and second connector parts are mated. The electricalconnection may be established in a protected oil or gel filledenvironment in the second connector part, such as a chamber. The chambermay be pressure balanced with respect to pressure outside of theconnector, for example by having a flexible wall. The second connectorpart may comprise an entry seal for receiving the contact pin. Thecontact pin may extend through the entry seal and into the secondconnector part when the connector parts are fully mated.

Other embodiments provide an underwater electrical connection assemblywith an improved design of a conductive member on a conductive core of acontact pin.

For example, one embodiment provides an underwater electrical connectionassembly comprising: a contact pin comprising an axially extendingconductive core with front and rear portions each having a respectiveelectrical contact surface, and an annular insulation portion aroundsaid conductive core extending axially rearwardly from the front portionof the conductive core; and a conductive sleeve mounted on the rearportion of the conductive core, the conductive sleeve having an abutmentsurface in engagement with the annular insulation portion, and aradially outer portion disposed radially outwardly of and forwardly ofthe abutment surface.

The radially outer portion can serve to shield the region where theconductive sleeve abutment surface is in engagement with the annularinsulation portion from electrical stress, as explained above.

The abutment surface may be arranged to hold the annular insulationportion in position relative to the conductive core. The abutmentsurface may extend annularly. The abutment surface may extend radially.For example, a radially inner portion of the abutment surface may be atthe same axial position as a radially outer portion thereof.

During assembly of the contact pin, the conductive sleeve may be movedforwardly on the conductive core, for example by being screwed thereon,so as to clamp the annular insulating portion between the front portionof the conductive core and the conducting sleeve in the axial direction.

It is preferred for the conductive sleeve to have an annular surfacewhich is slanted with respect to the axial direction, and which extendsradially outwardly from the abutment surface to the radially outerportion of the conductive sleeve.

Insulating material may be provided rearwardly of the abutment surface.During manufacture of the contact pin, such insulating material may beintroduced as flowable material. The annular insulation portion and theconductive sleeve may be engaged to form a closure at the front of aspace occupied by the insulating material, the space being to the rearof the abutment surface. This can assist during contact pin constructionto allow the space to be filled with flowable material without leakingforwardly of the abutment surface. The engagement of a metal conductivesleeve with an insulating sleeve made of plastics can form such aclosure.

Insulating material may be provided in a region rearwardly of theabutment surface. This region may be defined radially outwardly of theconductive core and radially inwardly of the conductive sleeve. Theinsulating material may be a solid material which has hardened from aflowable material.

The connection assembly may comprise a conductive socket member having asocket which receives the conductive core rear portion in electricalengagement with the rear electrical contact surface thereof. The socketmay be adapted for connection to another conductor, such as a conductorof a cable. The socket member may have a second socket for receivingsuch a conductor.

The assembly may comprise first and second connector parts capable ofbeing mated underwater, wherein the first connector part comprises thecontact pin as discussed herein. The second connector part may comprisea contact terminal for engagement by the electrical contact surface atthe front of the conductive core to establish an electrical connectionwhen the first and second connector parts are mated. The electricalconnection may be established in a protected oil or gel filledenvironment in the second connector part, such as a chamber. The chambermay be pressure balanced with respect to pressure outside of theconnector, for example by having a flexible wall. The second connectorpart may comprise an entry seal for receiving the contact pin. Thecontact pin may extend through the entry seal and into the secondconnector part when the connector parts are fully mated.

Other embodiments provide an underwater electrical connection assemblywith an improved earth guiding arrangement.

In the SpecTRON 10 assembly discussed above, the rear of the contact pinis encapsulated in a body of insulating fill material contained in achamber defined within a gland. A second, outer chamber is arrangedradially outwardly of the first mentioned, inner chamber, and has a walldefined by another gland the outside of which is exposed to ambientconditions. The outer chamber also contains insulating fill material.The arrangement allows external ambient pressure on the gland of theouter chamber to be transmitted via the gland to the outer chamber andthen via the gland of the inner chamber to the region surrounding therear of the contact pin.

Outside of the assembly the ambient water is at earth potential. On theother hand, the conductive core of the contact pin and the cableconductor are intended to carry high voltages, such as severalkilovolts. The contact pin is supported at an intermediate locationthereof by a metal support which is at earth potential. The contact pinhas an insulating sleeve which insulates the conductive core from theearthed support and is designed to withstand the high electrical stressacross its thickness. To the rear of the earthed support an insulatinginsert is provided around the insulating sleeve and is designed toaccommodate the electrical stress where the insulating sleeve emergesrearwardly from the earthed support. The insulating insert is insertedas a solid member around the contact pin. It forms a front wall of theinner chamber surrounded by the inner gland.

Such embodiments may provide an improved arrangement for dealing witheven higher voltages in an underwater environment as compared withconventional assemblies.

One embodiment provides an underwater electrical connection assemblycomprising: a contact pin comprising an axially extending conductivecore with front and rear portions each having a respective electricalcontact surface, and an annular insulation portion around saidconductive core extending axially rearwardly from the front portion ofthe conductive core; a chamber containing insulating fill material whichsurrounds the annular insulation portion of the contact pin where itextends axially rearwardly from a first axial position; and an earthguide member extending rearwardly from said first axial position to asecond axial position rearward of the first axial position, said earthguide member extending rearwardly from adjacent to the annularinsulation portion at said first axial position to radially outward ofsaid annular insulation portion at said second axial position.

In such an arrangement, the earth guide member can serve to control theelectric stress between the conductive core and itself, particularly inthe insulating fill material occupying the space in the chamber radiallyinwardly of the earth guide member and radially outwardly of the annularinsulation portion of the contact pin.

Electric stress is created in an insulator where there is a change ofelectric potential. In areas where electric potential changes over ashort distance, i.e. there is a high electric potential gradient, thenelectric stress is correspondingly high. The electric field is alsoinfluenced at the interface between two materials because of theirdifferent dielectric properties. In addition, where there is aninterface this has the risk that air pockets may be trapped and if theelectric stress exceeds a certain amount in air, typically 2 kV/mm, thenarcing may occur. A further possible issue is that if an underwaterassembly is compromised and a leak occurs, then water or othercontaminants may track along an interface between materials.

By providing an earth guide member extending rearwardly from a firstaxial position in relation to the contact pin the electric stress in thefill material radially inwardly of the earth guide member and outwardlyof the contact pin can be controlled. The electric stress can bedetermined based on the shape of the earth guide member, in particularits profile as viewed in axial cross section.

The earth guide member may be substantially conical. The cone mayincrease in diameter in the rearward direction. In certain someembodiments, as viewed in axial cross section, at least part of theearth guide member has a profile which is concave. For example, theearth guide member may have a concave profile towards its rear. In someembodiments, the earth guide member has a conical front part, with aprofile which in axial cross section is substantially straight, and arear part with a concave profile as viewed in axial cross section.

The rear of the earth guide member may be sealingly connected to a glandmember around the insulating fill material. The gland member may providea wall of the chamber containing the fill material. The gland member canserve to pressure balance the interior of the chamber to the pressureexternal of the gland member. A second chamber may be provided outwardof the first mentioned chamber and may also contain fill material. Thesecond chamber may have a wall the outside of which is exposed toambient pressure conditions to permit pressure balancing between theoutside and the inside of the wall. Thus the wall may comprise anothergland member. External pressure may therefore be transmitted via theouter gland member to the outer chamber and then via the inner glandmember to the chamber containing the insulating fill material whichsurrounds the annular insulation portion of the contact pin where itextends axially rearwardly from the first axial position.

The earth conditions around the contact pin may change in certainfailure or partial failure modes of the assembly. For example, if anouter chamber is provided and it is compromised so as to allow theingress of water then earth conditions are changed. For example thewater outside of an outer gland forms the earth in this region of theassembly under normal operating conditions, whereas if the outer chamberbecomes flooded or partly flooded then the water which has entered theassembly forms modified earth surroundings.

By providing an earth guide member as disclosed herein, electric stressin the region between the contact pin and the earth guide member andrearwardly of the first axial position, in the insulating fill material,can be kept substantially the same even if the earth conditionselsewhere in the assembly are changed due to a failure or partialfailure of sealing integrity.

The insulating fill material surrounds at least the annular insulationportion of the contact pin where it extends axially rearwardly from thefirst axial position. The provision of the earth guide member radiallyoutwardly of the fill material in this region avoids the need for aseparate insulating insert to be used. The fill material may be causedto surround the contact pin annular insulation portion by occupying thespace around the annular insulation portion when the fill material is ina flowable form. It may remain in flowable form, for example being inthe form of a gel or oil, but it may be a material which hardens, forexample to solid form. By using a fill material which is flowable whensurrounding the annular insulation portion, residual air pockets can beavoided. A fill opening may be provided for the introduction of fillmaterial to the chamber. After introduction the opening is closed andwill remain closed in normal use of the assembly.

One suitable insulating fill material is a silicone elastomer.

The shape of the conductive core radially inwardly of the earth guidemember is also relevant to the electric stress. In some embodiments, theconductive core has a portion of increasing diameter in the rearwarddirection, this portion being located radially inwardly of the earthguide member. Thus, as the earth guide member extends rearwardly,adjacent to the annular insulation portion at the first axial positionto radially outward of the annular insulation portion at the secondaxial position, the conductive core diameter may increase. This can bebeneficial, as discussed elsewhere herein, in allowing the rear portionof the conductive core to have a relatively wide diameter. Because theearth guide member, as it extends rearwardly, has an increasing radialdistance from the contact pin, the conductive core within the contactpin can itself increase in diameter without reducing the distancebetween the conductive core and the earth guide member. For example, theconductive core increasing diameter portion may be generally conical,with a diameter increasing in the rearward direction.

In certain arrangements, there may be a conductive sleeve mounted on therear portion of the conductive core. As discussed elsewhere herein, sucha conductive sleeve may provide a number of functions, such as thermaldissipation, electric stress control, and retention of an insulatingsleeve forming part of the annular insulation portion.

The conductive sleeve may extend forwardly to a position radiallyinwardly of the earth guide member. Thus the earth guide member canadvantageously control, or assist in controlling, the electrical stressin the region at the front of the conductive sleeve, which may be aregion where air pockets may in certain embodiments be trapped.

The connection assembly may comprise a conductive socket member having asocket which receives the conductive core rear portion in electricalengagement with the rear electrical contact surface thereof. The socketmay be adapted for connection to another conductor, such as a conductorof a cable. The socket member may have a second socket for receivingsuch a conductor.

The assembly may comprise first and second connector parts capable ofbeing mated underwater, wherein the first connector part comprises thecontact pin as discussed herein. The second connector part may comprisea contact terminal for engagement by the electrical contact surface atthe front of the conductive core to establish an electrical connectionwhen the first and second connector parts are mated. The electricalconnection may be established in a protected oil or gel filledenvironment in the second connector part, such as a chamber. The chambermay be pressure balanced with respect to pressure outside of theconnector, for example by having a flexible wall. The second connectorpart may comprise an entry seal for receiving the contact pin. Thecontact pin preferably extends through the entry seal and into thesecond connector part when the connector parts are fully mated.

Other embodiments provide a termination assembly for an underwater cablehaving an improved locking arrangement between a rear end portion of aconductive core of a pin and a conductive socket member for making anelectrical connection with a conductor of the underwater cable.

In the known SpecTRON 10 connector, it is known to terminate anunderwater cable to either of the receptacle and plug connector parts.In the case of a receptacle connector part, the rear end of the contactpin electrically connects to an underwater cable via a cable terminationassembly. In the case of a plug connector part, a pin is formed with asocket at its front end for receiving the electrical contact surface ofa contact pin of a receptacle connector part, and the rear end of thepin electrically connects to an underwater cable via a cable terminationassembly.

In each case, the cable termination assembly includes a conductive crimpsleeve having rear and front sockets. The rear socket receives aconductor of an underwater cable and is crimped thereon to establish amechanical and electrical connection. The front socket of the crimpsleeve receives a rear end portion of a conductive core of the pin(respectively belonging to a receptacle or a plug connector part), andthere is an electrical contact terminal in the front socket which makeselectrical contact with the rear end portion. The rear end portion ofthe conductive core is formed around the outside with an annular recess.The crimp sleeve is provided with a radial passage formed with a femalethread for receiving the male thread of a grub screw which has a frontend which locks in the annular recess of the conductive core, therebylocking the crimp sleeve to the conductive core. The locking arrangementprovided by the annular recess and the grub screw is located axiallyforwardly of the electrical contact terminal.

One embodiment provides a termination assembly for an underwater cable,comprising: a pin having an axially extending conductive core and anaxially extending annular insulation portion around said conductivecore; a conductive socket member for making an electrical connectionwith a conductor of an underwater cable and having a front socket, thefront socket receiving a rear end portion of the conductive core of thepin; an electrical contact terminal in the front socket makingelectrical contact with said rear end portion; and a locking member forlocking said rear end portion in the front socket, the locking memberbeing disposed rearwardly of the electrical contact terminal.

By providing the locking member rearwardly of the electrical contactterminal, the electrical flow path from the underwater cable to the pincan bypass the locking member. The electrical flow path may extend fromthe pin conductive core via the electrical contact terminal in the frontsocket of the conductive socket member, and via the conductive socketmember to the conductor of the underwater cable. If the pin conductivecore is damaged by the locking member, this does not necessarily affectthe electrical flow path because any such damage will likely occurrearwardly of the electrical contact terminal.

In the known cable termination assembly described above, the inventorsfound that the locking arrangement between the pin conductive core andthe crimp could lead to cracking during vibration testing of theassembly. Such cracking can lead to a loss of electrical continuity fromthe front end of the conductive core to the rear end portion where theconductive core makes electrical contact with the electrical contactterminal in the front socket of the crimp sleeve. This would have anegative effect on electrical performance.

The locking member may be arranged radially in a wall of the conductivesocket member. It may be in the form of a locking pin or locking screw,such as a grub screw, supported in a radial passage in the conductivesocket member. When the conductive socket member is to be locked to theconductive core, the locking member may be turned to cause it to moveradially inwardly to effect locking of the conductive socket member tothe conductive core. In some embodiments a plurality, e.g. three,radially arranged locking members may be provided.

The locking member may be arranged to engage the rear end portion of thepin conductive core directly. The locking member may engage anintermediate member, such as a shoe member, which is mounted on theconductive core of the pin. The locking member may extend radially in awall of the conductive socket member to engage the intermediate member.

By providing an intermediate member, this member may be formed of adifferent material from that of the conductive core and a material maybe selected for its mechanical rather than electrical properties,whereby the intermediate member has a reduced likelihood of beingdamaged by the locking member. In the known termination assemblydescribed above, the grub screw is made of steel and there was atendency for it to dent or even fracture the relatively soft copper ofthe pin conductive core.

Moreover, by using an intermediate member, it is possible to avoid thepresence of an annular recess in the conductive core. In the knowntermination assembly described above, such an annular recess results ina reduced cross-sectional area of the conductive core for flow ofelectrical current, with a resultant tendency for the reduced diameterportion to become a connector “hot-spot”. In general it is desirable tominimise temperature increases caused by increased electrical resistanceover the extent of the termination assembly.

The intermediate member may be a sleeve extending round the rear endportion of the conductive core. The intermediate member may be mountedto an axial rear end of the rear end portion of the conductive core.This can leave a major part, or all of, the axial extent of the rear endportion for making electrical contact with the electrical contactterminal in the front socket of the conductive socket member. This axialextent can be used for electrical connection rather than mechanicalconnection purposes.

The intermediate member may have an axial projection extending into anaxial socket in the rear end portion of the conductive core. Such anaxial socket can be provided without encroaching on the radiallyoutwardly facing surface of the rear end portion, thereby notcompromising the available area for electrical current flow. The axialprojection may be fitted into the axial socket by a force fit, by abayonet fit, or by some other fitting. The axial projection may be screwfitted into the axial socket.

In one embodiment, the intermediate member has an engagement portion forengagement by the locking member, the engagement portion having adiameter wider than the diameter of the axial projection. The provisionof a wider diameter engagement portion increases the available space forengagement by the locking member, ensuring a good mechanical connectioncan be obtained. A larger locking member may be used. For example, ifthe locking member is a locking screw or pin or the like, arrangedradially in a wall of the conductive socket member, then a widerdiameter engagement portion allows a larger diameter locking member tobe used.

The intermediate member may have a recess for receiving the lockingmember. Where plural locking members are provided, then pluralindividual recesses may be provided. The intermediate member may have anannular channel for receiving the locking member. In the case of plurallocking members, the same annular channel can serve to receive all thelocking members.

The intermediate member may be attached to the conductive core of thepin in various ways. The intermediate member may be screw mounted on theconductive core of the pin, for example by a screw thread provided onthe radially outwardly facing surface of the conductive core rear endportion, or by a screw fit of an axial projection of the intermediatemember into an axial socket in the rear end portion as described above.

The electrical contact terminal in the front socket of the conductivesocket member may be provided by the radially inwardly facing wall ofthe front socket. Thus the electrical contact terminal may be anintegral part of the conductive socket member. It may be a reduceddiameter portion of the front socket. However, the electrical contactterminal may be provided by a conductive contact cage received in thefront socket. The contact cage may ensure a tight fit and hence areliable electrical current flow path. It may have a certain resilienceto provide the fit. It may be of generally cylindrical form with axiallyextending slots.

The disclosed termination assembly can be used when the pin is part ofan underwater connector. The pin may therefore be part of a firstconnector part which is mateable under water with a second connectorpart having a contact terminal with which the pin makes an electricalconnection. It could also be used in a case where the pin is provided atthe back of a connector part, such as a plug connector part, whichitself provides a contact socket for receiving a contact pin of a firstconnector part, such as a receptacle connector part. The pin need notnecessarily be part of a mateable and demateable connector. Thus it maybe provided where a cable is to be terminated to a bulkhead or the like,and the pin may have a permanent or semi-permanent connection to anothercomponent at its front end.

Other embodiments provide a termination assembly for an underwater cablewith an improved arrangement for attaching together a cable terminationchamber housing and a housing for a pin to which the cable is to beelectrically connected.

In the SpecTRON 10 assembly discussed above, a housing for a cabletermination chamber is attached to a housing for a pin. The pin projectsrearwardly into the termination chamber where it is electricallyconnected to the front end of the cable. In a typical use of theassembly the pin housing is attached to another structure by a flangewhich has to be passed over the pin housing from rear to front, where itis bolted to the other structure. The flange is therefore formed with anopening which allows it to be passed over the pin housing wheninstallation on the structure is required. In order that the hole in thestructure engaging flange does not need to be excessively large, the pinhousing at the rear is designed to have a relatively small “footprint”when viewed in the axial direction. This posed a problem in how to forma secure and strong connection to the termination chamber housing. Thiswas dealt with by forming the termination chamber housing in two axiallysplit parts, known as a split bridge. Each part has at its front endhalf of a dovetail joint and the other half of the dovetail joint isprovided at the rear of the pin housing. When it is desired to assemblethe two housings together, each split bridge is engaged with the rear ofthe pin housing to complete the dovetail joint. The two split bridgecomponents are secured to each other and in order to tighten thedovetail joint the split bridge is pulled axially rearwardly relative tothe pin housing by a locking screw ring engaging a threaded portion atthe rear of the termination chamber housing, the locking screw ring alsourging an outer cylindrical sleeve of the termination chamber housingforwardly. The outer cylindrical sleeve has a front end which engagesthe contact pin housing which is thus urged forwardly by tightening ofthe locking screw ring relative to the split bridge which is pulledrearwardly. The dovetail joints are thereby placed in axial tension andmade secure.

The dovetail joint halves provided by the pin housing are radially insetfrom the outer cylindrical sleeve of the termination chamber housing andfrom the outermost diameter of the pin housing. It is therefore a simplematter to pass a flange over the pin housing, before it has beenattached to the termination chamber housing, from rear to front, thisflange then being used to secure the pin housing to the other structure.

One embodiment provides a termination assembly for an underwater cable,comprising: a cable termination chamber housing having an attachmentportion; a pin for electrical connection to the cable; a pin housing forthe pin; and an attachment flange for attachment to the pin housing soas to protrude radially therefrom, the attachment flange being forattachment to the attachment portion of the cable termination chamberhousing, and the attachment flange being provided in at least two partsso that when they are to be attached to the pin housing they can bemoved laterally into engagement therewith.

Such an arrangement can provide a stronger connection between thetermination chamber housing and the pin housing. It does not require theuse of a split bridge or dovetail joint. Moreover, it is possible tomaintain a relatively small “footprint” of the pin housing as viewed inthe axial direction, prior to engagement of the attachment flange withthe pin housing. When it is desired to install the pin housing toanother structure a suitable flange may be passed over the pin housingfrom rear to front, and then after that step the parts of the attachmentflange may be moved laterally into engagement with the pin housing.

The attachment flange may be bolted to the pin housing. The attachmentflange may be bolted to the termination chamber housing. In oneembodiment, the attachment flange is arranged to be bolted to the pinhousing in the radial direction and to be bolted to the attachmentportion of the termination chamber housing in the axial direction. Thetermination chamber housing may be provided with a suitable externalflange for receiving axial bolts. The pin housing may be provided withradial bolt holes for receiving radial bolts.

A radially extending dowel may be arranged to extend between each partof the attachment flange and the pin housing. Such a dowel can serve toimprove the torsional strength of the assembly. A radial hole may beprovided in the pin housing and a radial hole may be provided in theattachment flange part, allowing a dowel to be radially inserted.However this would require the hole in the attachment flange part to befilled after the dowel has been inserted and there may be a risk of thedowel falling out. It is therefore preferred to provide a dowelintegrally on the pin housing or on the attachment flange part. In oneembodiment a dowel extends radially outwardly from the pin housing andis received in a blind bore in the attachment flange part.

Two attachment flange parts may be provided. However, where a dowel isprovided integrally with either the pin housing or the circumferentiallyextending part, in order to permit assembly of the part onto the pinhousing only one dowel can be provided per part. It is thereforepreferred to provide at least three circumferentially parts. This canallow at least three dowels to be used, and hence allows for a strongerconstruction.

In one embodiment, exactly four attachment flange parts are provided.

The attachment flange parts may be arranged so as to extend partly roundthe pin housing, with intervals between the parts. However, thecircumferentially extending parts may extend around the pin housing inits entirety, without circumferential intervals. This maximises thespace available for bolts, dowels etc. and also serves to providetorsional rigidity.

The attachment flange parts may extend in the circumferential directionand have opposite circumferential ends. Each such end may be adjacent toan end of a circumferentially adjacent attachment flange part when allthe parts are attached to the pin housing.

At least one of the attachment flange parts may have a radially outerportion with a profile which is arcuate and concave. Such a concavearcuate profiled portion may assist in providing an axial “line ofsight” to a bolt head or the like for attaching a flange towards thefront of the pin housing to another structure. Such a line of sight canfacilitate tool access to the bolt or the like. A concave arcuateprofiled portion may be provided at a circumferential end of acircumferentially extending part, so that when two circumferentiallyextending parts are arranged circumferentially adjacent to each other,their concave arcuate profiled portions may be disposed adjacent to eachother. Each individual concave arcuate profiled portion may thencontribute only half of the space facilitating tool access. Where radialand axial bolts are provided for attaching the flange attachment partsto the pin housing and to the attachment portion of the cabletermination chamber housing, these may be inset from the circumferentialends of the flange attachment parts, and this inset space canadvantageously be used for positioning the concave arcuate profiledportions.

The disclosed termination assembly can be used when the pin housing ispart of an underwater connector. The pin housing may therefore be partof a first connector part which is matable under water with a secondconnector part having a contact terminal with which the pin makes anelectrical connection. It could also be used in a case where the pin isprovided at the back of a connector part, such as a plug connector part,which itself provides a contact socket for receiving a contact pin of afirst connector part, such as a receptacle connector part. The pinhousing need not necessarily be part of a matable and dematableconnector. Thus it may be provided where a cable is to be terminated toa bulk head or the like, and the pin may have a permanent orsemi-permanent connection to another component at its front end.

Underwater connectors as discussed herein in relation to any disclosedembodiment may be capable of being mated under water, and may also becapable of being demated under water.

Referring to FIGS. 1, 2 and 3, a first (receptacle) connector part 1 isshown. At the rear of the connector part 1 a cable termination chamberhousing 10 is secured to the contact pin housing 4 by a housingattaching arrangement 110.

FIG. 9 shows a second (plug) connector part 3, which is attached at itsrear to another cable termination chamber housing 10 by another housingattaching arrangement 110.

The connector part 1 has a centrally located and axially extendingcontact pin 2 supported in the contact pin housing 4. The housing 4surrounds the front part of the contact pin and forms a receptacle intowhich the second connector part 3, shown in FIG. 9, may be inserted. Thecontact pin has at its front end portion 6 an annularly extendingelectrical contact surface 8 forming an electrical contact terminal.

In use, the second connector part 3 will be inserted into the contactpin housing 4 of the first connector part 1 and the contact pin 2 willenter a chamber in the second connector part 3 where the electricalcontact surface 8 of the pin will engage in a corresponding electricalcontact socket of the plug connector part. Thus the connector parts 1and 3 together form a connector capable of being mated and dematedunderwater. This type of mating and demating arrangement is known, forexample from GB 2192316.

The contact pin 6 has an axially extending conductive core 5 which has afront end portion 7 providing the electrical contact surface 8, a rearend portion 11 providing a radially outwardly facing electrical contactsurface 13, and an intermediate portion 9 extending axially at anintermediate location between the front and rear portions.

At the rear of the connector part 1 the cable termination chamberhousing 10 is secured to the contact pin housing 4. An underwaterelectric cable 12 extends into the cable termination housing in a knownmanner. The front end of the cable 12 extends into a protectedenvironment within the cable termination housing 10. It passes firstinto an outer chamber which is contained by a generally cylindricalflexible gland 16. The outer chamber 14 is occupied by a fluid medium,such as gel or oil, which is a dielectric. The rear of the outer chamber14 is not shown but is sealed in known manner with respect to the cabletermination housing 10 and the jacket of the cable 12. The outside ofthe gland is exposed via suitable apertures in the cable terminationhousing 10 to ambient conditions, such as seawater. The flexibility ofthe gland 16 allows the outer chamber 14 to be pressure balanced withrespect to ambient pressure. At its front end the gland 16 has anannular lip 22 which is trapped between an inside surface of the cabletermination housing 10 and an outside surface of a contact pin supportmember 24. In this manner the front of the outer chamber 14 is sealinglyclosed.

An inner chamber 18 contains the front end of the cable 12, includingthe region where it makes electrical contact with a conductive socketsleeve 20. The inner chamber 18 has a flexible wall 26 the outside ofwhich is exposed to the fluid medium in outer chamber 14. The flexiblewall 26 has at its front end an annular lip 28 which is trapped betweenan inside surface of a cap 30 and an outside surface of an earth guidemember 32. The earth guide member 32 has a front end which engages withthe outside of the contact pin 2 by means of a pair of O-rings 34. Inthis manner the inner chamber 18 is sealed at its front end. At itsrear, the flexible wall 26 of the inner chamber 18 forms a stretch seal36 against the outside of the cable 12.

Towards the rear of the inner chamber 18 the flexible wall 26 has a pairof openings 38. One of these openings can be used during assembly of theconnector part to fill the inner chamber 18 with fill material, such asa silicone elastomer, whilst the other opening can be used for theescape of air from the chamber. Once the chamber is filed with fillmaterial the openings 38 are sealed closed. The fill material is capableof flowing during filling, so as to occupy, to the extent possible, allthe volume of the chamber 18, including small apertures, crevices andthe like. It may therefore be of a liquid consistency at the fillingstage. It is thus a flowable material. After filling, the fillingmaterial hardens to a solid form. Certain known silicone elastomers havethese properties and such a filling and hardening process is known inthe art.

The front of the cable 12 is dressed so that a central conductor 40thereof is exposed. The conductor 40 makes electrical connection withthe conductive socket sleeve 20 by a crimp 42 provided at the rear ofthe sleeve 20. Further details of the conductive socket sleeve 20 andits electrical and mechanical connection to the rear end portion 11 areshown in FIGS. 4, 5 and 6.

The conductive socket sleeve 20 acts as a socket member receiving therear end portion 11 of the conductive core 5 of the contact pin 6. Atits front end the sleeve 20 has a socket 44 in which is received aconductive contact cage 46 which forms an electrical contact terminalfor receiving the rear electrical contact surface 13 of the pinconductive core 5.

An axial bore 48 extends centrally into the rear of the conductive core5 and is formed with a female thread 50. Screwed into the bore 48 is amechanical shoe 52 so as to be mounted to the axial rear end of the rearend portion 11 of the conductive core 5. At its rear the shoe 52 has anengagement portion 58 with a wider diameter than the axial projection54. The engagement portion 58 has a radially outwardly facing annularchannel with which are engaged three grub screws 60. Each grub screw isformed with a male thread engaged with a female thread 64 formed in arespective radial passage in the socket member 20. Each grub screw 60acts as a locking member by its engagement in the annular channel of theshoe 58. The socket member 20 is locked to the contact pin 6 by the shoe52 acting as an intermediate member between the conductive core 5 andthe locking members in the form of grub screws 60. This mechanicallocking arrangement is disposed rearwardly of the region where theelectrical connection is made between the conductive core 5 and thecontact cage 46 in the socket member 20. Any fracturing or weaknesscaused to the mechanical connection need not therefore interfere withthe current flow path via the conductive core 5, the conductive cage 46and the socket 44.

In front of the electrical connection arrangement at the rear of thecontact pin 5, there is provided a conductive sleeve 68, secured to thecontact pin 2. Further details concerning the manner in which theconductive sleeve 68 is secured to the contact pin 2 are shown in FIGS.6, 7 and 8.

Adjacent to its front end the conductive sleeve 68 is formed with aninternal thread 70. A plurality of axial channels 72 are formed on theinner wall 74 of the sleeve 68 so as to interrupt the internal thread 70at circumferential intervals and allow communication of flowableinsulating material from in front of the sleeve 68 along its interior toan exit point 76 at its rear, as will be described in more detail below.

The contact pin 6 is provided with an axially extending annularinsulation portion 15 around its conductive core 5. The annularinsulation portion 15 extends from the front electrical contact surface8 of the conductive core 5 to the radially outwardly facing electricalcontact surface 13 at the rear of the pin. The annular insulationportion 15 includes, at least over part of its length, two layers. Thereis an insulating sleeve 17 and an inner insulating layer 19 which on itsinside surface is in contact with the conductive core 5 and on itsoutside surface is in contact with the insulating sleeve 17. Theinsulating sleeve 17 is a prefabricated member which during assembly ofthe contact pin, is passed over the conductive core from rear to front.At its front it forms a seal with the conductive core by means of a pairof O-rings 23. At its rear the insulating sleeve 17 is engaged by theconductive sleeve 68.

The conductive core 5 is formed at its front end with a central axialbore 80 which is closed by a plug 82. Immediately to the rear of thefront contact surface 13 of the conductive core 5, the conductive corehas a seal holding portion 5A on which the O-ring seals 21 are provided.To the rear of the seal holder portion 5A a cylindrical portion 5B isprovided. The cylindrical portion 5B has a diameter slightly smallerthan the inside diameter of the insulating sleeve 17 in this region.Forwardly of the cylindrical portion 5B a plurality of radial passages23 are formed to connect the axial bore 80 to the outside of theconductive core. An annular passage 25 is formed around the cylindricalportion 5B and inwardly of the insulating sleeve 17, by virtue of thedifference in diameters of these components in this region. To the rearof the cylindrical portion 5B the conductive core has a conical portion5C, reducing in diameter in the rearward direction. To the rear ofconical portion 5C the conductive core 5 has a cylindrical portion 5D ofrelatively small diameter compared to other parts of the conductive core5. Outwardly of the conical portion 5C and the cylindrical portion 5Dthere is an annular space 27 which is occupied by insulating materialforming the inner insulating layer. To the rear of cylindrical portion5D a second conical portion 5E is provided, increasing in diameter inthe rearward direction to where it joins another cylindrical portion 5F.The cylindrical portion 5F has a diameter which is smaller than theinsulating sleeve 17 thereby creating an annular passage between theoutside of cylindrical portion 5F and the inside of sleeve 17.

As seen more clearly in FIG. 7, to the rear of cylindrical portion 5Fthe conductive core 5 is formed with an annular recess 5G. This has adiameter smaller than that of the cylindrical portion 5F. To the rear ofthe annular recess 5G the conductive core 5 has a rear cylindricalportion 5H. At the rear of portion 5H the radially outwardly facingelectrical contact surface 13 is provided. The cylindrical portion 5Hhas a diameter slightly smaller than the inside diameter of theconductive sleeve 68 (described in more detail below), whereby anannular passage 31 is formed around the portion 5H.

The inner insulating layer 19 of the annular insulation portion isformed in the space 27 between reduced diameter portion 5D of theconductive core 5, as well as the conical portions 5C and 5E at therespective opposite ends of portion 5D, and the inside of the insulatingsleeve 17. The conductive core has an intermediate portion between itsfront and rear end portions which includes the cylindrical portion 5D.Around portion 5D the inner insulating layer formed by the solidifiedflowable material is at its thickest.

A split collar 84 engages in the annular recess 5G of the conductivecore 5. The split collar is formed with an external thread. It isnon-rotationally secured with respect to the conductive core by a pairof radially arranged dowels 86. The conductive sleeve 68 is screwed ontothe split collar 84 to adopt a position in which an annular abutmentedge 88 at the front of the conductive sleeve is in engagement with anannular groove 90 at the rear of insulation sleeve 17. The abutment edge88 is formed at an inner radius of the front of the sleeve 68. Thesleeve 68 has a radially outer portion 92 disposed forwardly of theabutment edge 88. An annular surface 94 extends between the abutmentedge 88 and the radially outer portion 92. The annular surface 94 isslanted with respect to the axial direction.

The outside diameter of the conductive sleeve 68 at its rear issubstantially equal to the outside diameter of the socket member 20. Inuse both of these components will be at the same electric potential andby forming them both of substantially the same diameter condensation ofthe electric field lines in the region between the front of the socketmember 20 and the rear of the sleeve 68 can be generally minimised,thereby reducing the risk of breakdown of the fill material occupyingthis part of inner chamber 18.

During manufacture of the contact pin 2, the insulating sleeve 17 ispassed over the conductive core from rear to front. The front of theinsulating sleeve 17 abuts against the wide diameter portion of theconductive core 5 which forms the electrical contact surface 13. Thesplit collar 84 is laterally assembled onto annular recess 5G andsecured against rotation by dowels 86. The conductive sleeve 68 isinserted over the rear of the conductive core and screwed into place.The annular abutment edge 88 at the front of the sleeve 68 engages withthe rear of the insulating sleeve 17. The insulating sleeve 17 isthereby clamped between the sleeve 68 and the front end of theconductive core 5 where the contact surface 13 is formed. Flowableinsulating material, such as a thermoplastic, is introduced into thecontact pin via the bore 80 at its front end. The flowable materialpasses from the bore 80 via the radial passages 23 and along the annularpassage 25 to the space 27. Once that space is occupied the flowablematerial continues along annular passage 29 and along axial passages 72in the conductive sleeve 68. From there the flowable material passesalong annular passage 31 until it reaches the exit point 76 from thesleeve 68. Normally this process is carried out with the contact pinheld vertically with its front end lowermost. Thus the flowable materialrises up the contact pin until eventually overflowing via exit point 76.Once the contact pin has been filled with the flowable material the plug82 is put in place. The flowable material solidifies to form an innerlayer 19 of the annular insulation portion.

The support 24 for the contact pin 5 is secured to the connector housing2 by a screw threaded connection. The support is made of a conductivematerial, which in this embodiment is metallic. The outside of theinsulating sleeve is bonded to an inner surface of the support 24. Thesupport has a forwardly extending tubular portion 96 which acts as anelectrically conductive earth shield around the annular insulationportion formed by insulating sleeve 17 and inner insulating layer 19. Atits rear the support 24 is generally cup shaped. It has a cylindricalcavity 98 which is screw threaded to provide a connection to the earthguide member 32. The earth guide member 32 extends rearwardly from afront portion 33 thereof where it is sealed by O-ring seals 34 to theinsulating sleeve 17 to a rear portion 35. The front portion 33 isdisposed radially outwardly of the cylindrical portion 5D of theconductive core 5. The rear portion 35 is disposed radially outwardly ofthe conductive sleeve 68. The earth guide member 32 is generallyconical, increasing in diameter from the front portion to the rearportion. Its profile in axial cross section is generally straight as itextends away from the contact pin, then becoming concave towards therear.

It is to be noted that the region of the conductive core 5 of thecontact pin where it increases from a small diameter to a largediameter, namely conical portion 5E, is disposed radially inwardly ofwhere the earth guide member is increasing in diameter in the rearwarddirection. A certain radial thickness of annular insulation is providedaround conductive core portion 5D so that the electric stress betweenthe core, which in use will be at a high voltage, and the support 24,which in use will be at earth, is below an allowable level. As theelectric field between the core and the earth “brakes out” from theannular insulation of the contact pin itself, in the rear part of innerchamber 18 occupied by fill material, it is important to control theprofile of the electric stress. The increasing diameter of the earthguide 32 in the rearward direction in the region where the contact pinenters the chamber 18 allows the conductive core 5 to increase indiameter, without an undesirable increase in electric stress.

Another area where care in the design of the embodiment has been takenin relation to electrical stress considerations is at the front end ofthe conductive sleeve 68. At this point there is the potential for thefill material occupying inner chamber 18 to leave small pockets oftrapped air. For example, air may be caught between the abutment edge 88of sleeve 68 and the annular recess 90 at the rear of insulating sleeve17. By providing radially outer portion 92 of sleeve 68 forwardly ofthis abutment region, the region is cloaked from changes in electricalpotential.

In addition, the region around the abutment edge 88 is radially inwardof the earth guide 32 where it is increasing in diameter and thisarrangement also serves to control the electric stress gradient.

In use, it is possible that the outer chamber 14 may experience ingressof water, for example if there is failure of the gland 16 or the sealsat its respective front and rear ends. The effect of this is that earthpotential radially outwardly of the rear of the contact pin, includingthe conductive sleeve 68, moves from the gland 16 to the flexible wall26. The earth guide 32 can effectively shield the part of inner chamber18 radially inwardly of the earth guide and so can control the electricstress even if the position of earth potential changes as a result ofsuch a failure or partial failure.

There will now be described the housing attaching arrangement 110 forattaching together the cable termination chamber housing 10 and thecontact pin housing 4. Whilst this is described primarily with referenceto FIGS. 1, 2 and 3, a similar arrangement 110 is used to attach thecable termination chamber housing 10 shown in FIG. 9 to the plugconnector housing 3.

The cable termination chamber housing 10 is formed near to its front endwith an attachment portion in the form of a flange 81. The contact pinhousing is formed near to its rear end with an annular recess 83. Anattachment flange 85 is provided in four parts 87, each of which eachextends in the circumferential direction around one quarter of a circle.Each flange part 87 is provided adjacent to its opposite ends in thecircumferential direction with a respective radial bolt hole 89.Corresponding bolt holes 91 are provided in the wall of the contact pinhousing 4 at intervals in the circumferential direction. A pair ofradial bolts 95 is provided for bolting each flange part 87 to thecontact pin housing 4 via the bolt holes 89 and 91. The bolt holes 91 inthe housing 4 extend radially inwardly from the bottom of the annularrecess 83. Projecting radially outwardly from the recess 83 four dowelpins 93 are provided. Each dowel pin 93 is positioned so that it willengage in a corresponding radial bore (not shown) of a respective flangepart 87. Since only one dowel pin 93 is provided per flange part 87, theflange part can be moved radially into engagement with the contact pinhousing 4, with a radially inwardly projecting portion 97 of the flangepart 87 engaging in the annular recess 83 of the housing.

Each flange part 87 is formed with a pair of axially extending boltholes 99 for receiving corresponding axial bolts 101. The flange 81 ofthe cable termination chamber housing 10 is provided with correspondingbolt holes 103 for receiving the bolts 101. The bolts 101 are used tosecure the flange parts 87 to the flange 81, thereby securely connectingtogether the contact pin housing 4 and the cable termination chamberhousing 10. The dowel pins 93 ensure torsional strength and rigidity ofthe connecting arrangement.

Prior to connecting housings 4 and 10 together, the housing 4 may beconnected to another structure. This may be done by passing a flangeover the contact pin housing 4, from rear to front. The axial profile ofthe housing is minimised by there being no attachment flange present atthis stage. The flange for connecting to another structure may forexample be positioned against shoulder 105 towards the front of thehousing.

What is claimed is:
 1. An underwater electrical connection assemblycomprising: a contact pin comprising an axially extending conductivecore with a front portion having a front electrical contact surface anda rear portion having a rear electrical contact surface, and an annularinsulation portion around said conductive core extending axiallyrearwardly from the front portion of the conductive core, the annularinsulation portion comprising an insulating sleeve; a collar mounted onthe conductive core forwardly of the rear electrical contact surfacethereof, the collar being axially split and having a radially outerthreaded surface; and a conductive sleeve having a radially innerthreaded surface in engagement with the radially outer threaded surfaceof the collar so as to mount the conductive sleeve on the conductivecore, the mounted conductive sleeve clamping the insulating sleevebetween the conductive sleeve and the front electrical contact surface.2. An assembly of claim 1, wherein the rear portion of the conductivecore, at least where the rear electrical contact surface is provided,has a diameter which is larger than that of a part of the conductivecore forwardly of the collar.
 3. An assembly of claim 1, wherein theconductive sleeve engages with the annular insulation portion.
 4. Anassembly of claim 1, wherein the conductive sleeve extends forwardly ofthe collar.
 5. An assembly of claim 1, wherein the conductive sleeveextends rearwardly of the collar.
 6. An assembly of claim 1, wherein thecollar is received in an annular recess around the rear portion of theconductive core.
 7. An assembly of claim 1, comprising an alignmentdowel extending radially between the conductive core and the collar. 8.An assembly of claim 1, wherein the conductive sleeve has an abutmentsurface in engagement with the annular insulation portion, and aradially outer portion disposed radially outwardly and forwardly of theabutment surface.
 9. An assembly of claim 1, comprising an axial channelextending from the front of the engaged radially inner and radiallyouter threaded surfaces to the rear thereof.
 10. An assembly of claim 9,wherein the axial channel is formed in the conductive sleeve.
 11. Anunderwater electrical connection assembly comprising: a contact pincomprising an axially extending conductive core with front and rearportions each having a respective electrical contact surface, and anannular insulation portion around said conductive core extending axiallyrearwardly from the front portion of the conductive core; and aconductive sleeve mounted on the rear portion of the conductive core,the conductive sleeve having an abutment surface in engagement with theannular insulation portion, and a radially outer portion disposedradially outwardly and forwardly of the abutment surface, the forwardlydisposed radially outer portion protecting from electric stress a regionwhere the abutment surface is in engagement with the annular insulationportion.
 12. An assembly of claim 11, wherein the conductive sleeve hasan annular surface which is slanted with respect to the axial direction,and which extends radially outwardly from the abutment surface to theradially outer portion.
 13. An assembly of claim 11, wherein insulatingmaterial is provided in a region rearwardly of the abutment surface. 14.An underwater electrical connection assembly comprising: a contact pincomprising an axially extending conductive core with front and rearportions each having a respective electrical contact surface, and anannular insulation portion around said conductive core extending axiallyrearwardly from the front portion of the conductive core; a chambercontaining insulating fill material which surrounds the annularinsulation portion of the contact pin where it extends axiallyrearwardly from a first axial position; an earth guide member extendingrearwardly from said first axial position to a second axial positionrearward of the first axial position, said earth guide member extendingrearwardly from adjacent to the annular insulation portion at said firstaxial position to radially outward of said annular insulation portion atsaid second axial position; and a conductive sleeve mounted on the rearportion of the conductive core, the conductive sleeve extendingforwardly to a position radially inwardly of the earth guide member. 15.An assembly of claim 14, wherein the earth guide member is substantiallyconical.
 16. An assembly of claim 14, wherein, as viewed in axial crosssection, at least a part of the earth guide member has a profile whichis concave.
 17. An assembly of claim 14, wherein the rear of the earthguide member is sealingly connected to a gland member around theinsulating fill material.
 18. An assembly of claim 14, comprising a fillopening for the introduction of fill material to the chamber.
 19. Anassembly of claim 14, comprising a second chamber outward of the firstmentioned chamber and containing fill material.
 20. An assembly of claim14, comprising a conductive sleeve mounted on the rear portion of theconductive core, the conductive sleeve extending forwardly to a positionradially inwardly of the earth guide member.
 21. An assembly of claim14, wherein the conductive core has a portion of increasing diameter inthe rearward direction, this portion being located radially inwardly ofthe earth guide member.
 22. A termination assembly for an underwatercable, comprising: a pin having an axially extending conductive core andan axially extending annular insulation portion around said conductivecore; a conductive socket member for making an electrical connectionwith a conductor of an underwater cable and having a front socket, thefront socket receiving a rear end portion of the conductive core of thepin; an electrical contact terminal in the front socket makingelectrical contact with said rear end portion; and a locking member forlocking said rear end portion in the front socket, the locking memberbeing disposed rearwardly of the electrical contact terminal; whereinsaid locking member engages an intermediate member which is mounted onthe conductive core of the pin.
 23. A termination assembly of claim 22,wherein said intermediate member has an annular channel for receivingthe locking member.
 24. A termination assembly of claim 22, wherein saidintermediate member is mounted to an axial rear end of the rear endportion of the conductive core.
 25. A termination assembly of claim 24,wherein said intermediate member has an axial projection extending intoan axial socket in the rear end portion of the conductive core.
 26. Atermination assembly of claim 25, wherein said intermediate member hasan engagement portion for engagement by the locking member, theengagement portion having a diameter wider than the diameter of theaxial projection.
 27. A termination assembly for an underwater cable,comprising: a pin having an axially extending conductive core and anaxially extending annular insulation portion around said conductivecore; a conductive socket member for making an electrical connectionwith a conductor of an underwater cable and having a front socket, thefront socket receiving a rear end portion of the conductive core of thepin; an electrical contact terminal in the front socket makingelectrical contact with said rear end portion; and a locking member forlocking said rear end portion in the front socket, the locking memberbeing disposed rearwardly of the electrical contact terminal; whereinsaid locking member engages an intermediate member which is mounted onthe conductive core of the pin; and wherein said intermediate member isscrew mounted on the conductive core of the pin.